Animal Feed Safety System

1
Animal Feed Safety System
P
Timothy E. Costigan Manager of Quality and
Analytical Services Prince Agri Products, Inc.
2
Mineral Premix System
P

• Controlled Formulations
• Computer Controlled Ingredient Addition
• Manual Double Checks
• Electronic Scale Records

3
Production System Checks
P

• Raw Materials
• Ingredient specifications based on
• Supplier process
• End use
• Known hazards
• Inbound ingredients sampled / retained for 1 year
• Scheduled chemical and physical analyses
• By lot, by shipment, by month
• Complete analysis (annual)

4
Ingredient Evaluation
P

• Analysis Requirement for Zinc Oxide
• Zn (formulated value)
• Pb, Cd, As (process issue / known hazards)
• Annual Review
• Analyses listed above
• Zn Metal (process issue)
• Dioxin (known hazard)
• Scan for 70 trace elements, densities, particle
  size, and moisture

5
Production System Checks
P

• Production Process
• Appearance check
• Batch yields
• Periodic analysis
• Batch samples are retained for 1 year
• Magnet inspection
• Inventory reconciliation

6
Records
P

• Custom formulas
• Tags/preprinted bags
• Mix records
• Scale records
• Receiving records

• Shipping records
• Load sheets
• Sales records
• Analytical records
• Audit records

Controlled Distribution Traceable through item
number / lot number
7
Traceability
P

• Ingredients
• Resale ingredients by suppliers lot number
• Consumed macro and trace ingredients by shipment
  (applied lot number)
• Consumed micro ingredients by suppliers lot
  number
• Finished Product
• By applied lot number

8
Biosecurity
P

• Visitors
• Must sign in and out, visitors tag issued
• Must be accompanied by an employee
• Employees
• Background checks before hiring
• Training of employees on procedure
• Materials
• Seals on inbound and outbound loads (sans LTL)
• Inspection of trailers, review of paperwork

9
Contamination Concerns
P

• Chemical
• Toxic elements (Pb, Cd, As, Hg)
• Cross contamination / incomplete blending
• Organic (pesticides, lubricants)
• Microbial and biological
• Limited concern (insects, rodents)
• Physical
• Metal and glass

10
Controlled Documents
P

• Document and Data Control (3)
• Purchasing (5)
• Product Identification and Traceability (2)
• Process Control (18)
• Inspection and Testing (17)
• Control of Inspections, Measuring and Test
  Equipment (5)

11
Controlled Documents
P

• Inspection and Test Status (3)
• Control of Nonconforming Product (1)
• Corrective and Preventive Action (2)
• Handling, Storage, Packaging, Preservation and
  Delivery (3)
• Control of Quality Records (1)
• Training (1)

12
Audits
P

• Production Personnel
• Monthly safety audits
• Weekly sanitation audits
• Periodic procedural audits
• Periodic dock audits
• Quality Unit
• Annual comprehensive audits
• Annual formulations audit

13
Statistical Techniques
P

• Yearly Mix Plant Error Assessments
• Raw Material Variation
• Ingredient Addition Error
• Mixing and Segregation Error
• Sampling and Analytical Error
• Semiannual Mixing System Evaluations
• Quarterly Bag Weight Studies

14
Analytical Work
P

• Ingredients
• Scheduled sample submission is based on
• Supplier history and the amount of shared data
• Ingredient variation / previous concerns
• Complete analysis yearly
• Premixes
• Every batch - safety or quality concern
• Single batch - process check
• Production issue

15
Overall Quality Program
P

• Apply portions of existing programs that apply
• HACCP for risk assessment
• ISO for document control, procedures
• GMP for hygiene, traceability, contamination
  issues
• Focus on preventative measures
• Ingredient quality
• Process evaluation
• Confirmatory testing